Headwear and Method for Manufacturing the Same

ABSTRACT

A headwear includes an outer panel including at least two fabric sheets connected at each opposite end portion; an inner panel including at least two fabric sheets connected at each opposite end portion; a shape forming panel being between the outer and inner panels, downwardly offset from a center axis of the outer and inner panels, and sewed on the inner panel. 
     With such a structure, since the margins between the outer and inner panels are far from the forehead and are separately disposed, the headwear may not compress a forehead. In addition, since the shape-forming panel may provide a variable cavity portion between the outer and inner panel, a headwear may have an excellent wearing comfort and a good design when it may come in close contact with the head.

BACKGROUND OF THE INVENTION

(a) Field of the Invention

The present invention relates to a headwear and a method for manufacturing the same. More particularly, the present invention relates to a headwear and a method for manufacturing the same having margins to be sewed between a head wearing portion and a visor portion in different directions. Accordingly, the headwear may not compress a forehead because the margins are separately disposed far from the forehead.

(b) Description of the Related Art

Generally, a headwear may include a head wearing portion for covering a head and a visor portion for shielding sunlight or the like, which is connected to a forward lower portion of the head wearing portion.

In addition, the headwear may further include a sweat absorbing member for absorbing the sweat from the forehead, in which the sweat absorbing member is disposed along the lower portion of the head wearing portion such that it comes in contact with the forehead.

FIG. 1A is a side view of a headwear according to prior art and FIG. 1B is a cross-sectional view of A portion of FIG. 1A.

As shown in FIG. 1A and FIG. 1B, the conventional headwear has a head wearing portion 100 and a visor portion 300 substantially orthogonally connected to each other.

Specifically, the conventional headwear has a thick and stiff connection portion between the head wearing portion 100 and the visor portion 300. It is because that a folded lower portion of an outer head wearing fabric sheet 110, a stiff and narrow tape member 120, an one sewed portion 350 of the visor portion 300, and an one end portion of a sweat absorbing member 400 are disposed and sewed in one direction altogether.

The outer head wearing fabric sheet 110 forms an outer panel of the head wearing portion 100 and has a margin 130 to be seamed at the folded lower portion.

The tape member 120 has a width of about 7 mm width and is disposed in the folded lower portion of the outer head wearing fabric sheet 110. It is difficult to fold the lower portion of the outer head wearing fabric sheet 110 since it is thin and soft. Accordingly, when the lower portion of the soft outer head wearing fabric sheet 110 is folded along the stiff tape member 120, the tape member 120 may have stiffness so that it helps the folding of the lower portion of the soft outer head wearing fabric sheet 110.

Meanwhile, the visor portion 300 includes an outer visor fabric sheet 310, an inner visor fabric sheet 330, and a core member 320 disposed between the outer visor fabric sheet 310 and the inner visor fabric sheet 330. The core member 320 may have a predetermined thickness and stiffness such that it maintains the visor portion 300. Both end portions of the outer visor fabric sheet 310 and the inner visor fabric sheet 330 are respectively sewed to each other so as to envelop the core member 320 therein. At this time, a margin 130 to be sewed with the first margin 130 of the outer head wearing fabric sheet 110 is disposed near to the forehead.

Ultimately, the margin 130 of the head wearing portion 100, the stiff tape member 120, and the margin 350 of the visor portion 300 are entirely sewed opposite to each other and are disposed altogether. Accordingly, the conventional headwear may compress the forehead by the thicker and stiffer margins.

And then, the sweat absorbing member 400 may be further disposed opposite to the outer head wearing fabric sheet such that it comes in contact with the forehead. Accordingly, at least 6-layer fabric sheets are overlapped and sewed near to the forehead so as to combine the head wearing portion 100, the visor portion 300 and the sweat absorbing member 400. Thus, the conventional headwear may provide compression feel on the forehead when the wearer puts on the same.

In addition, since the tape member 120 has a stiffness so as to maintain a size of the headwear, the conventional headwear may provide a severe compression feel when the tape member 120 comes in contact with the forehead.

In addition, since the conventional headwear has the head wearing portion 100 and the visor portion 300 connected substantially orthogonally to each other, the head wearing portion 100 may not come in contact with the forehead. Also, a clearance may be irregularly formed between the head wearing portion and the head, and accordingly, the conventional headwear may be easily slipped off the head or may be crumpled when the size of the headwear is adjusted.

The above information disclosed in this Background section is only for enhancement of understanding of the background of the invention and therefore it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY OF THE INVENTION

The present invention has been made in an effort to provide a headwear and a method for manufacturing the same having advantages of continuously and smoothly combining a head wearing portion with a visor portion.

In addition, the present invention has been made in an effort to provide a headwear and a method for manufacturing the same having advantages of having a variable cavity portion to provide a cushion on the forehead and closely covering the head.

An exemplary embodiment of the present invention provides a headwear. The headwear includes an outer panel including at least two fabric sheets connected at each opposite end portion; an inner panel including at least two fabric sheets connected at each opposite end portion; a shape forming panel being between the outer and inner panels, downwardly offset from a center axis of the outer and inner panels, and sewed on the inner panel.

The at least fabric sheet may include an outer head wearing fabric sheet and an outer visor fabric sheet and the outer panel may be formed by sewing a first margin of the outer head wearing fabric sheet with a second margin of the outer visor fabric sheet. At this time, the outer head wearing fabric sheet has the first margins at the lower end portion thereof and the outer visor fabric sheet has the second margin at the upper end portion thereof. The shape forming panel may include a core member having a predetermined strength and a tape member having a predetermined elastic force along a vertical direction thereof and the tape member being sewed on the one end portion of the core member near to the forehead. The tape member may have a fixed end portion (a third margin) elastically connected with one end portion of the core member and a free end portion disposed near to the forehead. The third margin may be separately disposed from the first margin and the third margin is downwardly offset from the second margin. The shape-forming panel may form a cavity portion based on a center axis thereof between the outer and inner panels. The inner panel may include an inner visor fabric sheet and an inner head wearing fabric sheet and the inner panel is formed by sewing a fourth margin of an inner head wearing fabric sheet on the backside of the inner visor fabric sheet, the inner head wearing fabric sheet having the fourth margin at the lower end portion thereof. The fourth margin may be downwardly offset from the first margin and the fourth margin is separated from the second and third margins. The outer head wearing fabric sheet may be the same material as the outer visor fabric sheet. The headwear may further include a sweat absorbing member on the inner panel near to the forehead.

Another exemplary embodiment of the present invention provides a method for manufacturing a headwear including forming an outer panel by smoothly connecting an outer head wearing fabric sheet to an outer visor fabric sheet, forming a shape-forming panel by combining a core member with a tape member, the core member having a predetermined strength and the tape member having an elastic force in a vertical direction; combining the shape-forming panel on an inner visor fabric sheet; forming an inner panel by combining an inner head wearing fabric sheet on the back surface of the inner visor fabric sheet; and, sewing both end portions of the outer and inner panels.

The forming of the outer panel may include the outer head wearing fabric sheet having a first margin upwardly folded at a lower portion thereof, the outer visor fabric sheet has a second margin downwardly folded at an upper portion thereof, and sewing the first and the second margins opposite to each other. The forming of the shape-shaping panel may include the tape member having a third margin folded at an fixed end portion thereof and sewing the third margin on the one end portion of the core member, the core member having a predetermined strength and the tape member having an elastic force in a vertical direction. The third margin may be separated from the first margin and be downwardly offset from the second margin. The shape-forming panel may form a variable cavity portion based on a center axis thereof between the outer and inner panels. The variable cavity portion become larger when the outer head wearing fabric sheet or the outer visor is fabric sheet is pulled in a direction crossed the center axis. The forming of the inner panel may include the inner head wearing portion having a fourth margin folded at the lower end portion thereof and sewing the fourth margin on the back surface of the inner visor fabric sheet.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a perspective side view of a headwear according to a prior art. FIG. 1B is a cross-sectional view taken along an A portion of FIG. 1A.

FIG. 2A is a perspective side view of a headwear according to an exemplary embodiment of the present invention. FIG. 2B is a cross-sectional view taken along a B portion of FIG. 2A.

FIG. 3A to FIG. 3F are respectively a schematic cross-sectional view showing a process for manufacturing the B portion shown in FIG. 2A.

DETAILED DESCRIPTION OF THE EMBODIMENTS

As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.

FIG. 2A is a perspective side view of a headwear according to an exemplary embodiment of the present invention. FIG. 2B is a cross-sectional view taken along a B portion of FIG. 2A.

According to an exemplary embodiment of the present invention, it is one example that a visor is used as the headwear, and accordingly, whatever to put on the head, for example, a baseball cap or a hat may be used.

According to an exemplary embodiment of the present invention, the headwear may include a head wearing portion 1 for putting on a wearer's head and a visor portion 3 for shielding sunlight. The visor portion 3 is smoothly connected to the head wearing portion 1.

The head wearing portion 1 may include an outer head wearing fabric sheet 5 and an inner head wearing fabric sheet 7. It is not limited thereto, but the head wearing portion 1 may include a sweat absorbing member 20 along with the inner head wearing fabric sheet 7 or instead of the inner head wearing fabric sheet 7.

The visor portion 3 may include an outer visor fabric sheet 9, an inner visor fabric sheet 11, and a core member 13 disposed between the outer visor fabric sheet 9 and the inner visor fabric sheet 11. The core member 13 may have preferably stiffness such that it helps the visor portion 3 maintaining a predetermined shape.

Particularly, the head wearing portion 1 may be continuously and smoothly connected to the visor portion 3 as shown in FIG. 2A. At this time, it is preferable that the outer head wearing fabric sheet 5 is the same material as the outer visor fabric sheet 9.

However, it is one example that the outer head wearing fabric sheet 5 is the same material as the outer visor fabric sheet 9, and accordingly, the outer head wearing fabric sheet 5 may be different from the outer visor fabric sheet 9.

As shown in FIG. 2B, the outer head wearing fabric sheet 5 and the outer visor fabric sheet 9 respectively has a first margin 6 and a second margin 10 at each end portion folded opposite to each other. Since the first margin 6 and the second margin 10 are inwardly and oppositely disposed, the first margin 6 and the second margin 10 may not be exposed and not be overlapped when the first margin 6 is oppositely sewed with the second margin 10.

According to an exemplary embodiment of the present invention, a tape member 30 is used, which has a wider width than the conventional tape member 120, for example, it has about 10cm width. The tape member 30 has a fixed end portion elastically connected with one end portion of the core member 13 and a free end portion 31 disposed near to the forehead. The core member 13 is disposed on the inner visor fabric sheet 11 between the outer visor fabric sheet 9 and the inner visor fabric sheet 11. A combination of the tape member 30 and the core member 13 forms a member for forming a variable cavity portion 50 a, which is hereinafter referred to as “a shape-forming panel 50”. The shape-forming panel 50 may be elastically moved along a vertical direction (near to the forehead or far from the forehead in FIG. 2A) when the head wearing portion 1 or the visor portion 3 is pulled so as to put on and off the headwear. It is because that the tape member 30 and the core member 13 may have a predetermined elastic force in a vertical direction.

Specifically, the shape-forming panel 50 is formed by sewing the fixed end portion(a third margin) 32 on the core member 13 along with the inner visor fabric sheet 11 while downwardly folding the fixed end portion 32 of the tape member 30 by a predetermined width. The fixed end portion 32 and the free end portion 31 are divided by a sewing portion 33 along a center axis C-C between the head wearing portion 1 and the visor portion 3. The sewing portion 33 may combine a center of the tape member 30 with the inner visor fabric panel 11. That is, it is preferable that a length L of the fixed end portion 32 is the same as that I of the free end portion 31 and the fixed end portion 32 is disposed toward the visor portion 3. It is because the shape-forming panel 50 may easily form a variable cavity portion 50 a when the visor portion 3 is downwardly pulled. In addition, the shape-forming panel 50 may provide a soft and light feel on the forehead because the free end portion 31 is disposed near to the forehead.

In addition, the tape member 30 reinforces a connection of between the inner visor fabric sheet 11 and the inner head wearing fabric sheet 7 as well as it provides a clearance between the outer visor fabric sheet 9 and the core member 13. It is one example that the fixed end portion 32 of the tape member 13 is downwardly folded, and accordingly, the fixed end portion 32 of the tape member 13 may not be folded.

According to an exemplary embodiment of the present invention, the inner head wearing fabric sheet 7 may have a fourth margin 21 folded by a predetermined width at the lower end portion thereof. The fourth margin 21 is sewed on the back surface of the inner visor fabric sheet 11 along with the free end portion 31 of the tape member 30. It is preferable that the fourth margin 21 is disposed just near to the center axis C-C and it may provide a sewing portion 34 far from the forehead.

With such a structure, the first margin 6 of the outer head wearing fabric sheet 5, the second margin 10 of the outer visor fabric sheet 9, the third margin 32 of the tape member 30, and the forth margin 21 of the inner head wearing fabric sheet 7 or the sweat absorbing member 20 are separately arranged. Thus, the head wearing portion 1 may be continuously and smoothly connected to the visor portion 3.

In addition, the outer head wearing fabric sheet 5 and the inner head wearing fabric sheet 7 are sewed at the other end portions 15 thereof far from the forehead, and also the outer visor fabric sheet 9 and the inner visor fabric sheet 11 are sewed at the other end portions 16 thereof far from the forehead. Accordingly, the headwear according to an exemplary embodiment of the present invention may provide a slim design.

Since the first, second, third, and forth margins 6, 10, 31, and 34 having a weight and a protrusion are far from the forehead and are disposed near to the center axis C-C of the headwear, the headwear may not compress a forehead and may provide a good wearing comfort.

Meanwhile, the shape-forming panel 50 may form and maintain the variable cavity portion 50 a based on a center axis C-C passed though the sewed portion 8 between the outer head wearing fabric sheet 5 and the outer visor fabric sheet 9. Since the shape-forming panel 50 is elastically moved in a vertical direction when the outer head wearing fabric sheet 5 or the outer visor is fabric sheet 9 are pulled vertically or horizontally (in a direction crossed the center axis C-C), the variable cavity portion 50 a may become larger to provide a more cushion on the forehead. In addition, the headwear may provide a good wearing comfort since the headwear may closely cover the head due to an elastic force of the shape-forming panel 50.

A method for manufacturing a headwear according to an exemplary embodiment of the present invention will be described in detail with reference to FIG. 3A to FIG. 3F.

FIG. 3A to FIG. 3F are respectively a schematic cross-sectional view showing a process for manufacturing the B portion shown in FIG. 2A.

According to an exemplary embodiment of the present invention, an outer panel of the headwear may include the outer head wearing fabric sheet 5 and outer visor fabric sheet 9. The outer head wearing fabric sheet 5 is upwardly folded at the lower end portion thereof such that the first margin 6 is formed with a predetermined width. The outer visor fabric sheet 9 is downwardly folded at the upper end portion thereof such that the second margin 10 is formed with a predetermined width. And then the first and second margins 6 and 10 are disposed opposite to each other and sewed therebetween by the sewing portion 8 (for example, a thread) as shown in FIG. 3A. That is, when the first and second margins 6 and 10 are connected by with the sewing thread 8, the outer panel is formed.

As shown in FIG. 3B, the shape forming panel 50 is formed by combining the tape member 30 on the one end portion of the core member 13. At this time, the tape member 30 is folded at the lower end portion thereof to form the third margin 32. The third margin 32 is sewed by a thread 32a on the one end portion of the core member 13.

As shown in FIG. 3C, the shape forming panel 50 is disposed on the inner visor fabric sheet 11. The shape forming panel 40 is sewed with the inner visor fabric sheet 11 at the sewing portion 33 of the tape member 30 and also it is sewed with the inner fabric panel 11 at the other end portion 16 of the core member 13. The sewing portion 33 is substantially positioned along the center axis C-C.

That is, the free end portion 31 of the tape portion 30 is sewed on the inner visor fabric sheet 11 by the sewing thread 33 and the other end portion 16 of the core member 13 is sewed on the inner visor fabric sheet 11.

As shown in FIG. 3D, the inner head wearing fabric sheet 7 or the sweat absorbing member 20 is upwardly folded at the lower end portion thereof such that the fourth margin 21 is formed. Ultimately, an inner panel including the inner head wearing fabric sheet 7 and the inner visor fabric sheet 11 is formed by sewing the fourth margin 21 on the backside of the inner visor fabric sheet 11 by the sewing thread 34. At this time, the sewing thread 34 is passed though the free end portion 31 of the tape member 30 and is disposed nearer to forehead than the sewing thread 33.

As shown in FIG. 3E, the outer panel and the inner panel are respectively connected at both end portions by a sewing thread 39.

As shown in FIG. 3F, the both end portions of the outer panel and inner panel may be sewed while covered by fabric sheets 15 a and 16 a. Accordingly, the headwear may provide a clear appearance without the exposed and loosed seams.

According to an exemplary embodiment of the present invention, the head wearing portion 1 may include the outer head wearing fabric sheet 5 and the inner head wearing fabric sheet 7, but it is not limited thereto. Accordingly, the head wearing portion 1 may further include the sweat absorbing member 20 between the outer fabric panel 5 and the inner fabric panel 7.

In addition, a method for manufacturing a headwear according to an exemplary embodiment of the present invention may be applied to manufacture a baseball cap, a visor, a hat, an elastic headwear without a size adjuster, and a headwear having a size adjuster or the like.

While this invention has been described in connection with what is presently considered to be practical exemplary embodiments, it is to be understood that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

According to an exemplary embodiment of the present invention, since the head wearing portion may be continuously and smoothly connected to the visor portion, the headwear may provide a slim design corresponding to the head shape.

In addition, since the seamed margins between the head wearing portion and the visor portion are far from the forehead, the headwear may not compress the forehead.

According to an exemplary embodiment of the present invention, since the headwear has a shape forming panel between the outer panel and inner panel thereof, the headwear may provide a cushion on the forehead and may provide a good wearing comfort. 

1. A headwear comprising: an outer panel including at least two fabric sheets connected at each opposite end portion; an inner panel including at least two fabric sheets connected at each opposite end portion; a shape forming panel being between the outer and inner panels, downwardly offset from a center axis of the outer and inner panels, and sewed on the inner panel.
 2. The headwear of claim 1, wherein the at least fabric sheet includes an outer head wearing fabric sheet and an outer visor fabric sheet and the outer panel is formed by sewing a first margin of the outer head wearing fabric sheet with a second margin of the outer visor fabric sheet, the outer head wearing fabric sheet having the first margins at the lower end portion thereof and the outer visor fabric sheet having the second margin at the upper end portion thereof.
 3. The headwear of claim 1, wherein the shape forming panel includes a core member having a predetermined strength and a tape member having a predetermined elastic force along a vertical direction thereof and the tape member being sewed on the one end portion of the core member near to the forehead.
 4. The headwear of claim 3, wherein the tape member has a fixed end portion (a third margin ) elastically connected with one end portion of the core member and a free end portion disposed near to the forehead.
 5. The headwear of claim 4, wherein the third margin is separately disposed from the first margin and the third margin is downwardly offset from the second margin.
 6. The headwear of claim 1, wherein the shape-forming panel forms a cavity portion based on a center axis thereof between the outer and inner panels.
 7. The headwear of claim 1, wherein the inner panel includes an inner visor fabric sheet and an inner head wearing fabric sheet and the inner panel is formed by sewing a fourth margin of an inner head wearing fabric sheet on the backside of the inner visor fabric sheet, the inner head wearing fabric sheet having the fourth margin at the lower end portion thereof.
 8. The headwear of claim 7, wherein the fourth margin is downwardly offset from the first margin and the fourth margin is separated from the second and third margins.
 9. The headwear of claim 2, wherein the outer head wearing fabric sheet is the same material as the outer visor fabric sheet.
 10. The headwear of claim 1, further comprising a sweat absorbing member on the inner panel near to the forehead.
 11. A method for manufacturing a headwear comprising: forming an outer panel by smoothly connecting an outer head wearing fabric sheet to an outer visor fabric sheet; forming a shape-forming panel by combining a core member with a tape member, the core member having a predetermined strength and the tape member having an elastic force in a vertical direction; combining the shape-forming panel on an inner visor fabric sheet; forming an inner panel by combining an inner head wearing fabric sheet on the back surface of the inner visor fabric sheet; and, sewing both end portions of the outer and inner panels.
 12. The method for manufacturing a headwear of claim 11, wherein the forming of the outer panel includes the outer head wearing fabric sheet having a first margin upwardly folded at a lower portion thereof, the outer visor fabric sheet having a second margin downwardly folded at a upper portion thereof, and sewing the first and the second margins opposite to each other.
 13. The method for manufacturing a headwear of claim 11, wherein the forming of the shape-shaping panel includes the tape member having a third margin folded at an fixed end portion thereof and sewing the third margin on the one end portion of the core member, the core member having a predetermined strength and the tape member having an elastic force in a vertical direction.
 14. The method for manufacturing a headwear of claim 13, wherein the third margin is separated from the first margin and is downwardly offset from the second margin.
 15. The method for manufacturing a headwear of claim 11, wherein the shape-forming panel forms a variable cavity portion based on a center axis thereof between the outer and inner panels.
 16. The method for manufacturing a headwear of claim 15, wherein the variable cavity portion become larger when the outer head wearing fabric sheet or the outer visor is fabric sheet is pulled in a direction crossed the center axis.
 17. The method for manufacturing a headwear of claim 1, wherein the forming of the inner panel includes the inner head wearing portion having a fourth margin folded at the lower end portion thereof and sewing the fourth margin on the back surface of the inner visor fabric sheet. 